Polyfuran foams and a method of preparing same

ABSTRACT

A synthetic foam and a process for its preparation is disclosed comprising (a) a polymerized mass of at least 50 parts by weight of furfuryl alcohol, at least one part by weight of at least one amino compound selected from the group consisting of urea, thiourea and melamine, and up to 49 parts by weight formaldehyde, and (b) an equal or less amount of filler.

United States Patent n 1 Larsen et al.

[ Nov. 11, 1975 [54] POLYFURAN FOAMS AND A METHOD OF PREPARING SAME [75] Inventors: Hans-Ole Larsen, Hvidovre'. Sven Barfoed, Copenhagen, both of Denmark; John Arthur Gooch Gent. Liphook. England [73] Assignee: Wolff 84 Kaaber, Forum. Denmark [22] Filed: Aug. 14. 1973 [2l] Appl. No.1 388.168

[30] Foreign Application Priority Data Aug. 25. I972 United Kingdom 39707/72 [52] US. Cl. 260/2.5 F; 260/l5; 260/175;

[51] Int. Cl. C08J 9/14; C08J 9/08 [58] Field of Search 260/70 A. 2.5 F. 829

[56] References Cited UNITED STATES PATENTS 3.222.315 l3/l965 Singer. 260/70 A LAVA .A'A'AVAVAVA 'AVAVAVAVAVAVAVAVAVA w en'a'exezeze vvAvAmvv.

XYAVAVA AVAA VAVAVAVE 3.360.492 l2/l967 Tsou..... 260/ A 3.390.107 6/1968 Tzlshlick et al. 160725 F 3.506.599 4/]970 Dean /2 5 F 3.779955 12/1973 Wade 260/25 F Primary fimminer-Morton Foelak Attorney. Agent. 0/ FirmLa\\'rence Rosen; E. Janet Berry [57] ABSTRACT A synthetic foam and a process for its preparation is disclosed comprising (a) a polymerized muss of at least 50 parts by weight of furfur \l alcohol. zit least one part by weight of at least one amino compound selected from the group consisting of urea. thioureu 21nd melamine, and up to 49 parts h weight formuldehyde. and (b) an equal or less amount of filler.

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8K 87 8 8 8 w 8 3 8 on on 8 52 ON o POLYFURAN FOAMS AND A METHOD OF PREPARING SAME The present invention relates to an improvement in the process of preparing polyfuran foams by polymerizing, alternatively copolymerizing furfurylalcohol, if desired in combination with prepolymers, alternatively precopolymers of furfurylalcohol in the presence of a strong acid.

It is known to prepare rigid foams from urea formaldehyde with and without the inclusion of small amounts of furfurylalcohol, but the known foams are prepared by complicated processes, and the foams have a number of disadvantages limiting their use. The manufacture of rigid foam from urea-formaldehyde resins has become a well-developed art in recent years. While there are a number of modifications thereof employed in the preparation of the foams, the conventionally observed process concerns basically that of preparing an aqueous foam-like suspension of a urea-formaldehyde condensation product with the aid of a surface active agent. The suspension is aerated until it has the density which will give the type of product having the cellular structure desired. The foam suspension is then contacted with an acid catalyst, and cures preferably under the influence of elevated temperatures, which facilitates the hardening and partially frees the water used in preparing the aqueous suspension.

The removal of water from the foam severely limits the production capacity of a given plant and puts a limit to the size of foam blocks which can be made. According to U.S. Pat. No. 3.006.87l the maximum density of urea-formaldehyde foam which can be made is about 30 kg/m, as higher density foams will show severe cracking during the drying operation.

All of the urea-formaldehyde foams generally suffer in that they are inherently relatively fragile and possess comparatively low resiliency and abrasion resistance characteristics.

According to US. Pat. No. 3.006.871 the fragility observed for urea-formaldehyde resin foams while mainly inherent in the nature of the condensate, is believed to be influenced by the mechanism with which the contained water leaves the aqueous foam during the hardening and drying procedure. According to said patent this influence can be reduced, and foams having superior and improved physical properties can be obtained by using urea-formaldehyde condensates modified with furfurylalcohol or furfural. The amount of furfurylalcohol employed is between 5 and 50 parts by weight per 100 parts by weight urea-formaldehyde condensate.

The foams produced by the modified urea formaldehyde condensates are claimed to have higher abrasion resistance and resilience than the unmodified foams. The foams are, however, still typical urea-formaldehyde foams with low compressive strength, low resistance to hydrolysis, and predominantly open cell structure. Also the process of their preparation includes the drying step with the undesirable consequence described above.

A new process for preparation of foams from urea formaldehyde condensate similarly modified with furfurylalcohol is disclosed in British Pat. No. 942,845. According to said patent a solid compound which generates a gas by reaction with an acid is mixed with the co-condensate prior to hardening. Preferred compounds for use as blowing agent are carbonates and bicarbonates, which liberate carbon dioxide upon contact with the acid hardener which may be for instance phosphoric acid. The molar ratios of urea to formaldehyde and of urea to furfurylalcohol of the cocondensate employed in the process are 1:16 and l:0.9. respectively. The foams obtained by the process of said patent are chemically of the same type as those obtained by the process of US. Pat. No. 3.006.871. A serious defect of the new process is that the acid hardener must perform two competing functions. One is as a catalyst in the hardening process of the cocondensate, and the other is reacting with the bicarbonate, whereby the catalytic effect is destroyed which makes control of foam density. cell size. and cure extremely difficult.

Furfurylalcohol resins prepared by the polymerisation or condensation of furfurylalcohol alone or in conjunction with formaldehyde are used for the manufacture of rigid cellular furan foams in the process of US. Pat. No. 3.390.107. According to said patent a rigid cellular expanded material may be obtained by a process which comprises expanding a preformed liquid furan resin containing low amounts of furfurylalcohol monomer in the presence of an acid catalyst and a blowing agent. The acid catalyst may be phosphoric acid and the blowing agent trichloro trifluoroethane. The cellular materials prepared have densities in the range of about 16 to 56 kg/m, and are of a partially open cell structure. Although the process is an improvement over the processes of US. Pat. No. 3.006.871 and British Pat. No. 942.845 the production of the foam includes the complicating step of preparing a high viscosity liquid furan resin and a postcure of the foams by heating, to ensure complete cure of the resin. and the foams have only moderate performance in various fire tests such as the muffle furnace test and the propane torch test. According to our copending application 43.033/71 said undesirable features may be avoided, and a foam material having additionally several desirable properties may be obtained by polymerizing furfurylalcohol in one step. if desired in combina tion with prepolymers or precopolymers of furfurylalcohol in the presence of an acid catalyst, provided that at least 50 percent of the hydroxy groups present in the furfurylalcohol prepolymer mixture originate from free furfurylalcohol.

Foams of densities down to 2 kg/m showing improved performance in various fire tests and having very fine cell structure with large amounts of closed cells are obtained.

The density of the foams can be controlled by the amount of prepolymer in the furfurylalcohol. higher amount of prepolymer giving higher densities. it is, however, found that as the amount of prepolymer is increased the performance in the fire tests decreases, and foams prepared from furfurylalcohol/prepolymer mixtures in which less than 50 percent of the hydroxyl groups originate from the furfurylalcohol monomer show insufficient performance. For many applications foams of higher densities having high compressive strength and being less friable are desired.

It was found, that novel foams comprising:

a. parts by weight of polymer of which at least 50 parts by weight of the material is derived from furfurylalcohol and at least one part by weight from at least one amino compound selected from the group consisting of urea, thio urea and melamine together 3 with up to 49 parts by weight of material derived from formaldehyde. and

B. up to I parts by weight of a filler. alternatively an filler. have improved load bearing capacity and several other desirable features. They may be obtained from A) furfurylalcohol. if desired in the presence of B) prepolymers of furfuryl alcohol by using as a third component C) an amino formaldehyde resin in an amount corresponding to more than 1 part by weight of the amino compound. whereas the final foam still has to contain more than 50 parts by weight bound furfuryl alcohol per 100 parts by weight of A B +-C. the amino compound being selected from the group consisting of urea. thio-urea and melamine. excluding any combinations in which the parts by weight of A per I00 parts by weight of resin (A B C plus twice the parts by weight of C per 100 parts by weight of resin (A B +C) are less than 20. The furan foams thus modified show higher compressive strength than unmodified furan foams at the same density. and the modified foams can be prepared in much higher densities and obtain good performance in the fire tests.

An additional advantage of the modified furan foams as compared to the modified urea-formaldehyde foams ofU.S. Pat. No. 3006.871 and British Pat. No. 942.845 is that they can be prepared by the well-known oneshot" technique used for preparing rigid polyurethane foams. that is in the absence of water and bicarbonate. The reason for this is probably that the amino formaldehyde furfuryl alcohol blends and/or condensates useful in the preferred process of the present invention have a suitable reactivity. Preferably the foam according to the invention contains a polymer having a composition falling within the area ABCDE of FIG. I. In said triangular diagram the compositions by weight of the polymer part of the foams a are shown.

The coordinates in parts by weight per 100 parts by weight of resin are to be understood as:

1. Amino compound: material derived from an amino compound.

2. Formaldehyde: material derived from formalde hyde.

3. Furfuryl alcohol incl. furan-resin: material derived from furfuryl alcohol.

It is not intended that the term furan resins are used herein be restricted to the furan prepolymers resulting from the sole condensation of furfuryl alcohol. Thus, for example. other appropriate furan resins include precopolymers of furfuryl alcohol and furfural. or of furfuryl alcohol and formaldehyde. or of furfuryl alco' hol. formaldehyde and phenol. or of furfuryl alcohol. formaldehyde and an aminocompound.

The foams of the present invention are found in the lower right corner of the triangle corresponding to more than 50 parts of furfuryl alcohol incl. furan-resin and more than l part of amino compound.

Particularly preferred are foams containing a polymer having a composition falling within the area WXYZ of FIG. 1. The molar ratio of the material derived from formaldehyde to the material derived from an amino compound is preferably between l:l and 6:1. Preferably the source for the material derived from an amino compound is urea. In a preferred embodiment the filler [3 has reacted with the polymer 0:. Particularly preferred is a filler consisting of a material containing hydroxyl and/or carbonyl groups. More particularly 4 filler B is a lignin containing material. In a very useful product filler B is lignin sulfonate.

In the present process ureaformaldehyde furfuryl alcohol resins having a urea formaldehyde ratio of l:l till 1: l0. and a urea 1 furfuryl alcohol ratio of 1: at least l. are used generally as urea-formaldehyde resins. Very useful urea-formaldehyde furfuryl alcohol resins have a urea formaldehyde ratio of l:l till 1:6. Preferably at least l0 parts by weight of urea-formaldehyde resin per 100 parts by weight of A B C are used. Said ureaformaldehyde furfuryl alcohol resins are prepared according to known methods. In this connection reference is made to British Pat. No. 942.845. US. Pat. No. 3.006.87l. Belgian Pat. No. 619.879 and British Pat. No. 930.236.

Though the product according to British patent application 43.033/71 (NFZ) has many desired properties. some of the products have the defect of the newly discovered so-called second exotherm. A second exotherm reaction starts in foams prepared from high concentrations of furan resins when heated to about 200 C and due to the resulting high temperature said foams are destroyed. This second exotherm constitutes a fire risk and it has been discovered that for instance commercial phenolic foams show second exotherm.

A test for determining whether the second exotherm reaction will be developed is carried out in the following way.

A sample is cut with dimensions 6 X 6 X 6 cm. The sample is placed in the middle of an oven. the temperature of which is kept at 200 C A thermocouple is in serted in the middle of the sample and the temperature of the foam recorded. In foams having a second exotherm the temperature of the foam will rise above 200 C and the maximum temperature is noted.

Foams containing a resin composition according to FIG. 2 (The triangular diagram of FIG. 2 has the coordinates: Furfuryl alcohol. Furan-resin, and Urea-formaldehyde resin; the base-line. corresponding to foams without ureaformaldehyde resin. represents foams made according to US. Pat. No. 3.390. l0? and our copending No. 43.033/7l.). excluding any compositions within the area .IKLM of said figure, particularly foams having a composition falling within FIG. 2, excluding any compositions within the area FGHI of said figure. can be made free of a second exotherm.

The second exotherm of foams prepared from a) furfuryl alcohol. b) furan resin. and c) UFF resin (1:313) is voided by incorporatingthe component C, as appears from the comparative example XI mentioned here below. Foams having a composition falling within area PQRS of FIG. 3 have still a second exotherm, even if component C is present. However, the second exotherm reaction of said type of foams may be reduced considerably by adding to the foamable mixture a reactive filler, particularly a filler having hydroxyl and/or carbonyl groups, more particularly a lingin derivative containing filler and very particularly by using lignin sulphonate. having a higher density. Preferably the reactive filler has a particle size of which at least percent will pass through a British standard sieve of 72 mesh. The proportion of filler generally used is up to l00 parts by weight per parts by weight of resin.

All unmodified NF2 foams are found at the baseline of FIGS. 1, 2 and 3 corresponding to 0 parts of ureaformaldehyde furfuryl alcohol resin.

From the examples it appears that foams can be made over a broad range of component ratios. with or without ammonium lignin sulphonate.

Variation in component ratios results in variation in foam properties. so desired properties can be obtained by selecting proper foam formulations.

The density can be increased by 1. high levels of furan resin;

2. high levels of ammonium lignin sulphonate.

From FIG. 3 (in the diagram with the coordinates furfuryl alcohol. furan-resin. and UFF-resin having a molar ratio of 1:313. is shown the area inside which the foams of example Xl have second exotherm. The effect of type and amount of filler is demonstrated by the size of the areas. With high levels of lignin sulphonate a wider range of component ratios can be used to prepare exothermfree foams compared to foams with talc and low levels of lignin sulphonate. It also appears. that the foams with second exotherm are concentrated in the lower left corner of the triangle. corresponding to high levels of furan resin. Those resin compositions giving foams having a second exotherm can be expressed Furan resin more than 45 parts plus UFF resin parts.

Even at furfuryl alcohol levels as low as l() parts, the exotherm can be removed by 20 parts of UFF resin having a molar ratio of 1:313.

From FIG. 3 appears. that in case the ammonium lignin sulphonate is replaced by talc. the second exotherm is still concentrated in the area of high level of furan resin. The amount of UFF resin having a molar ratio of 1:3:3 needed in this case to remove the exotherm at a constant level of furan resin is about parts by weight.

From FIG. 6 (In the diagram the formulations of the foams in example XXXV are shown using as coordinates: furfuryl alcohol. furan-resin and urea formaldehyde-furfuryl-alcohol-resin (l:3:3).) appears that low density foams 20 kg/m") are found only in the areas of a. less than 40 parts of furan resin.

b. more than parts of furfuryl alcohol.

A borderline can be drawn separating foams with densities below and above kg/m. This line represents 40 parts of furan resin.

It has appeared that a more exact indication of the nonflammability may be obtained by determining the critical oxygen index, as defined in ASTM D 2863 (critical oxygen index is the minimum concentration of oxygen, expressed as volume percent, in a mixture of oxygen and nitrogen that will just support combustion of a material under the conditions of said method), than by using the propane torch test as used in the prior British patent application 43.033/7l.

It appears from the examples, that the critical oxygen index is dependent on foam formulation. however the foams according to the invention have an unexpected high critical oxygen index.

Two types of end-points have been observed, i.e. flash over and burning. In some cases the burning was followed by afterglow. Burning and afterglow are found in foams having a second exotherm. Said foams contain more than parts by weight of furan resin and less than 25 parts by weight of urea-formaldehyde furfuryl resin.

EXAMPLE I A urea formaldehyde-furfurylalcohol resin was prepared according to the method described in British Pat. No. 942.845. Example No. l. The molar ratio of Urea: formaldehyde: furfurylalcohol was I 2.6 0.9.

100 g of the resin was mixed with 5 g sodiumbicarbonate whereupon 22 g of o-phosphoric acid was added under vigorous stirring. However. due to the instantaneous reaction between the acid and the bicarbonate. the gas-evolution started before the resin and the catalyst were properly mixed. and a foamed material having a very irregular cell-structure was obtained. The foam had a density of about I00 kg/m. was hard and brittle with very coarse cells.

in another experiment [00 g of the resin and 5 g of sodiumbicarbonate were mixed with 24 g of catalyst consisting of 8g of o-H F'O (87 /r). 4 g of H and 12 g of isopropanol. The resulting foam was similar to the above mentioned. in order to be able to obtain a proper mixing of the resin and the catalyst and thereby improving the cell-structure. bicarbonate was replaced by an organic liquid volatizing during the polymerization.

lOO g resin were mixed with l2 g of tricloro-trifluor ethane S g of o-phosphoric acid (87%) were added.

After 2 seconds of mixing the foaming started. The resulting foam showed a severe shrinkage and a poor cell-structure. To a similar mixture of resin and blowing agent was added a catalyst consisting of 5 g of a mixture of o-phosphoric acid (87%). conc. sulfuric acid and isopropanol (2: l :3 p.b.W. The creamtime was 18 see. which was sufficient for a good mixing of resin and catalyst. The mixture expanded to about 50 times its original volume but due to the slow cure the foam showed a severe shrinkage. and the final foam showed a density of over kg/m. Due to the high reactivity of the resin the amount of catalyst could not be increased in order to overcome the slow cure responsible for the shrinkage.

EXAMPLE ll A number of foams were prepared with broad variations in the composition of the polymer. The formula tions are stated together with properties of the foams in table A below. The foams were made by mixing urea formaldehyde furfuryl alcohol resin prepared accord ing to example Xlll. Furan-resin prepared according to example X1], and furfuryl alcohol and adding to the mixture a surfactant. a blowing agent and a filler. ln Foams nos. a to 0 further urea and/or formaldehyde was included in the resin. To this mixture was added under vigorous stirring the catalyst consisting of a mixture of acids in butanediol. When catalyst and resin were properly mixed. the mixture was poured into an aluminium mould with dimensions X 200 X 50 mm and allowed to rise. The foams cured rapidly and no aftercure was needed. C reamand risetime were noted and shrinkage was measured by an internal scale from 0 (no shrinkage) to 3 (severe shrinkage, collapse). The foams were cut and cell-structure characterized by the homogenity scale going from 0 (no splits or voids) to 3 (a number of small splits and/or a few voids). The den sity of the foams was measured and in some cases the 10 percent compressive strength was measured using the ASTM-test D 1621-64. All of the foams are of good quality and have improved abrasion resistance over the known foams. From Table A it can be seen that the properties of the foams can be varied by changing the composition of the polymer. Generally foams with low content of furfuryl alcohol and high content of furanresin tend to be a little more hard and brittle and to have at slightly coarser cell structure. whereas foams containing low amounts of furfuryl alcohol and low content of furan-resin have a very fine cell structure and \cry small cells. Also these foams are more 8 the present invention. whereas foams no f-u are foams modified with an aminocompound (urea) and having a composition falling within the claims of the present patent application. The foams were made using the technique described in example II.

The compressive strength of the foams is depicted in FIG. 5. which clearly shows that foams modified with urea l have much higher strength at comparable densities than foams without urea (2 TABLE A Composition of poly mer. parts per A B c D E F o H 1 .I 11 L r11 P Q R s T 5 35 1111 7.1 17.5 17.9 1 37.5 311 3 111 79 49 1 11 13.59 LI 1 -1 311 1111 911.11 1 7.19 1.11 311 3 111 35 71 11 11 19.911 1' 111.5 31 1119.5 11111- 1 311 3 111 311 911 1 11 33.117 g 13.5 311.3 1111.3 11111 1 311 3 111 37 113 1 11 13.119 11 111.19 111.3 73 11111 311 311 3 75 11 35 311 47 1 11 34.311 11.43 1 5.4 11.1 1111.5 1111 11111 311 3 75 11 1 111 s1 1 11 45.37 11.119 5.4 11.1 x115 .111 411 .911 3 75 11 35 57 44 1 11 111.44 11.11 k 1.35 3.113 911.113 311 1411 411 3 75 11 411 45 17 11 11 711.16 1.4 1 1.35 3.113 911.3 311 11111 1111 3 11 511 39 11 11 11 511.11 1.3

A. l-oam .\1

B L'rea L formaldehyde I) hirturyl .ilcohul ttkl furan Yufltt l- L H--resin l3? 1 l 11r.111re\in (i l urt'uryl alcohol H Silicone l Lrca J formaldehyde k ammonium ltgnm -ulph111talc l n-Hemnc .\l HJUFIMSUI lA Butanetliol 4.1.4 5 H 1P0, H 1S(). ho ropanol 4.2.11 0 Cream time sec P Rise time sen. U Shrinkage R Hulnogenity S Density. kg m" l' l11'1 eontpressiu: strength. kgcm the urea-formaldehyde l'urt'urylaleohnl resin used in this foam had a molar ratio of l 4 4.

tough and resilient and show better resistance to vibra- EXAMPLE W tional fatigue.

From foams no. 1' and j appears that foams having the Very good foams have been made using different fill same composition can be made with different densities 5 ers. In table C typical results of using an inorganic nonusing different formulations. The foams showed very reactive filler, talc. and an organic reactive filler. liggood performance in fire tests. For instance burn ninsulphonate. are given. through times in the US. Bureau of Mines Propane All foams have a fine cell-structure and good me- Torch Test were 5 to 10 times those of commercial chanical properties. It is demonstrated that the use of phenol formaldehyde foams. 5 ammonium lignin sulphonate in place of tale makes it 1 possible to prepare foams of higher density from same EXAMPLE ll] 1 rf evel of fu urylalcohol.

Two series of foams were prepared using the formu- It is also evident that ammonium lignin sulphonate lations given in table C. The foams no 1H are furan increases the risetime of a given formulation. which is a foams prepared according to known procedures, ac- 55 definite advantage in the production of moulded articording to US. Pat. No. 3.390.l07 and British patent cles. application 43.033/71. Their compositions are outside TABLE C Composition of polymer part per parts of polvmer AB CDE F GHIJKLMNOPORS a 3.9 911.1 311 311 3 1 111 11 34 9.11 11.1111 11 3.9 911.1 35 15 3 1 111 11 34 13.1 11.11 c 3.9 911.1 411 111 3 1 111 11 34 111.4 11.13 11 3.9 911.1 45 5 3 1 111 11 34 37.7 11.19 11 3.9 911.1 511 11 3 1 111 11 34 411.11 11.33 1 4.4 11.3 1111.11 35 511 1 5 11 34 13.11 11.33 5.9 11.9 115.3 35 33 1 5 11 13 37.5 119* E 11.1 9.3 114.11 511 45 15 1 311 111 11 31 33.7 11.711 1 4.7 7.1 1111.3 711 91 39 3 45 11 43 111.5 11.37

TABLE C-continued Composition of polymer part per lllll parts of ih mer AB CDE F GHIJKLMNOPQRS j (1.8 1U.) 83A 7U 2 45 h 42 I78 (L47 k 4.7 7.| 894.2 70 9] 39 I 45 f1 41 V9.8 (154 l 4.7 7 l 88.2 70 9| 39 I 75 6 42 35.2 (1.54 m 6.8 H); 83.] IOU 92.3 7.7 I 75 6 4:. 31.6 t). K n 6.8 I01 831 70 I20 Ill I 45 h 41 45.5 L56 0 L 2. 96.6 20 I41) 4 2 75 (1 4H 76.2 1.40 A Foam Mr B [ten (1 Formaldehyde D: Furl'ur \l alcohol incl. funtn resin E: L'FFresin 1:313 F Furzm-resin G: Furfuql alcohol H: Pzlrnlhrmaldehxde l: Silicone surfactant J: Tillcum K: ammonium lignin sulphnnate L: carbon-black M: Phenol N: Freon H3 ()1 n-Hemne P: H,,PO.H. .SO. isuprupnnol 412:6 Q: H .PO.H. .SO. L4 Butunedinl 4:2:45 R: Density kgim" S: llli compressive strength. lag/cm *5') compressive strength.

TABLE D Composition of polvmer A B C D E F G H l .I K L M N O P Q R a L35 2.0 96.6 EU IOU R0 75 I 6 5U 38 5 25.4 (I 5-H) 2L3 h 3.4 5.] 9L6 50 7U 8U 75 I 6 4 4'4 13 N12 2 505 4-9.3 c HLK lfij 73.0 [60 Ill 20 75 2 6 I5 49 13.4 S 2 29(1 Iii} d 1.35 lil 96.6 EU H10 30 75 I 6 39 9 5].] 160 l 1.4 e 3.4- 5.l 91.6 50 70 Kt) 75 2 (1 40 57 33 lb 7 5 "z 705 49.4 f L8 [6.3 73.1) IN] 2U 2U 75 I ('1 15 38 48 N 1 S 2 671) 19.5

A: Foam No. B; L'reu parts (z Formaldeh ule parts D: Furluql alcohol incl. lunm resin E: L'FFresin |:3:3 F: Furnn resin 0: Furfi|r \l alcohol H: Tulcum l: ammonium lignin sulphunnte J: Silicone K: n-Hexune L: H PO.H. .SO. l.-l Butanediul 4:1:45 M: cream time sec. N: Rise time sec. 0: Densit kg/m" P: Shrinkage 0: Time to burn through in sec. R: Time to hum through tu unit densit sec/kglm" Tm commercial phenol formnkleh} Lie foams of densil I I .l) and l7.7 kg/rn gnu: times to burn through ul- 31.1 and 3 l .0 seconds. respectively EXAMPLE V A foam was prepared using EXAMPLE VI 120 g of Urea-formaldehyde-furfurylalcohol resin (molar ratio 1:313) A foam was prepared using the same components as 50 g of F uran-resin in example V. except that icing sugar was replaced by 30 g of F urfurylalcohol wood flour (75 g).

2 g of Silicone-surfactant The foam had a density of 15.3 kg/m and a l0 per- 6 g of n-Hexane cent compressive strength of QM kglcm The celland as filler structure was good and the foam was tough.

75 g of icing sugar (ground sucrose).

. EXAMPLE VI! The components were well mixed and -5 g o a catalyst. consisting of phosphoric acid, sulfuric acid and 1,4 A foam was prepared using the same components as Butanediol (4214.5) was added under rapid stirring. The foam had a density of 51.7 kg/m and a 10 percent compressive strength of 2.12 kglcm The cell-structure was good and the foam was tough.

in example V except that icing sugar was replaced by potato flour. The foam had a good cell-structure with an average cell size of microns. a density of 22 kg/m and a compressive strength of 0J9 kg/cm EXAMPLE vlll A foam was prepared using the same components as in example Vl except that wood flour was replaced by 75 g of lignin-derirative (Borrebon Special from Borregaard. Norway The result was similar to the results of example Vl.

EXAMPLE IX EXAMPLE XI Foams were prepared using the formulations given in the table E. In FIG. 4 the component ratios are shown on a triangular diagram. Maximum temperature of the second exotherm was determined on the foams using the technique described in the introductory part of the present specification. Independent of the type and amount of filler. the foams having second exotherms in this example it is demonstrated that good foams W are found in the lower left corner of the triangle diacan be made with very different proportions of the gram. corresponding to high levels of furan-resin and three polymer components: urea-formaldehyde resin. low levels of urea-formaldehyde-furfurylalcohol resin. furfurylalcohol and furfurylalcohol resin. As urea-for- The exact borderline between exotherm free foams and maldehy de resin two urea-formaldehyde-furfurylalfoams with second exotherm is dependent on the type cohol resins with molar ratios of the three components of urea formaldehyde resin and amount of filler. being 1 3 3 and l 4 4' The furan resin is prepared A comparison of foam No. 5 and No. 6 shows that the according to example lo. second exotherm is removed by substituting talc with The formulations used are given in table D below. All ligninsulphonate. the foams show good homogenity. fine cell-structure Acomparison of foams with different levels of ligninand fine resistance to vibrational fatigue. S lphonate as filler shows that the second exotherm is Foam densities are dependent on the formulations reduced or removed by increase in the level of filler. and can be varied over a broad range by selecting the In FIG. 3 the areas are shown in which the foams of proper proportions of the three polymer components. this example have a second exotherm. The exotherm It is also demonstrated that the type and amount of areas are found in the lower left corner of the triangle filler is an important factor which has a strong inlluand the effect of type and amount of filler is demonence on the foam-properties. strated by the different size of the areas.

Table E.

u h l ll L j' a ll l A Ill ll H nt-on 4o no I31) so So loo loo so 2o loo so on Ll-l -rcsin l3U 4U loll i.4i4 l uran-rcsin l-ltl ('0 it] TN lIll Ill 40 71) Hill It) 40 ("nil l-Hl :(l l'urt'uryl 2o lo (\ll so so 2o on so so 2o so lo 2o 2o alcohol silicone 2 2 2 2 2 2 2 2 2 2 2 2 2 surfactant lignin- 7s 7s 75 75 4o 4o 4o 75 75 75 sulphonalc talc 75 75 75 75 n Hc\anc h f h o (7 6 b b 6 (1 h (l 6 6 H m n sm IA 25 2 2* 4o so 25 25 4o 55 25 3o 2 3o 25 Butanediol (41114.5) cream time. up 4: 73 57 34 as so 49 4s 55 x7 52 so on \LL. rise time 73 7x as 31 s 4o 3a 13 7 42 as no ms 144 SCU- tlt-nslo. x23 32.4 255 m7 -37 l3.-l lfL-l 1a.: 5L9 2os 121) 44.7 86.4 43,7 lo k lm EXAMPLE X Two commercial phenol formaldehyde foams showed very heavy second exotherm when tested simi- Foams we re prepared using the same formulations as lar to the foams above. The maximum temperatures rein example IX, but replacing the furan-resin. prepared corded were 580 and 595C and the evolution of heat according to example XVlll by a commercially availand smoke continued for'a considerable time. able furan'resin. (Durez 16470. from Hooker Chemical EXAMPLE X" S.A.. Belgium).

Results similar to the results of example IX were ob- Preparation of furan-resm. tained. 35 kg of furfurylalcohol and 10 kg of water TABLE F l 2 i 4 s a 7 a 9 lo ll l2 l3 l4 l5 UFF-resin 1:313 20 4o 50 3o 4o 40 3o 40 40 so so so 100 so loo Furan resin l5o no no no loo loo 12o no mo 7o loo loo 4o loo 2o Furfuryl alcohol 2o 2o so so so so so 2o no so 4o 2o so 20 2o Silicone surfactant 2 Z 2 2 2 2 2 2 2 2 2 2 2 1 Z Lignin sulphonate 75 75 75 75 4U 4U 75 75 4U 4U Talc 75 75 75 5 n-Hexane o o n o e 6 s 6 o h 6 a o o r H;,PO4:H- -SO,: 1:4 Butanediol 25 2s 25 5o 25 25 so so so 4o 2s 30 3s 30 25 TABLE F-continued 1 2 3 4 5 o 8 9 ll) 1 l 12 13 I4 15 Density. kg/m 105 82.3 43.6 50.5 56.0 18.4 33.3 39.6 31.9 16.7 47.5 18.5 16.4 23.8 21! t4 l lamemperuture of 2nd exotherm C 415 275 221) 461) 210 311) 575 355 540 200 200 :on 2011 201) 205 was charged to a 45 1 reaction vessel equiped with mantle. stirrer. thermometer. and vacuum destillation equipment.

The mixture was heated to 65C and sulphuric acid (1 normal) was added until a pH between 2.4 and 2.5 was reached. During the entire reaction period the pH was measured and kept at 2.4 2.5. After 5 hours the temperature was raised to 85C. The reaction was fol lowed by measuring the refractive index of the resinphase. At a refractive index of 1.5400 the reaction was stopped by neutralizing with sodiumhydroxide. The aqueous layer was separated and discarded. and residual water removed by vacuumdistillation. The resin was a clear red-brown liquid having a viscosity of 1.250 cps (C) and an OH-equivalent weight of 356. This furan-resin and other resins prepared by this method have been used in a number of the above mentioned foams.

EXAMPLE XIII Preparation of ureaformaldehyde-furfurylalcohol resin.

6.25 kg of urea,

9.35 kg of paraformaldehyde. and

30.4 kg of furfurylalcohol (molar ratio 113:3) was mixed in a 45 1 reaction vessel equipped with stirrer, heating and cooling mantle. thermometer and vacuum-distillation equipment. 100 ml of 4 N ammoniumhydroxyde was added.

The temperature was kept at 90C and the pH kept between 9 and 10 for 2.5 hours by addition of 4 N sodiumhydroxide. The temperature was then lowered to 80C and the pH changed to 2.5 by addition of 4 N sulphuric acid. When the viscosity of the mixture had increased to 300 cps (25C) the mixture was neutralized with sodium hydroxide and water was removed by vac uum distillation. The product was a clear yellow resin having a viscosity of around 25.000 cps. The OH-value determined after a standard procedure was 408.2 corresponding to an OH-equivalent weight of 137.5. This resin has been used in a number of the above mentioned examples.

EXAMPLE XIV A resin was prepared similarly to the resin in Example Xlll except that furfurylalcohol was replaced by propyleneglycol.

A foam was made by mixing 80 g of the resin.

100 g of furan-resin,

20 g of furfurylalcohol,

2 g of silicone surfactant,

75 g of lignin sulphonate,

6 g of n hexane. and as a catalyst, V

g of a mixture of o-phosphoric acid (87%) sulphuric acid. and 1.4-Butanediol (weight ratio 4 2 4.5).

Creamtime was 153 sec., rise time 237 sec. Density of the foam 109 kg/m". The foam showed no second exotherm. and had very good mechanical properties and a fine cell-structure. After the exotherm test. that is 30 min. at 200C, the mechanical properties of the foam were still very good.

EXAMPLE XV Using the method of example XIII a resin was pre pared using.

1.8 kg of area.

3.8 kg of paraformaldehyde.

l 1.8 kg of furfurylalcohol (molar ratio 1 4 4) The resin obtained was very similar to the resin of example XIII. Foams prepared using this resin are mentioned in example IX. (l. m and n).

EXAMPLE XVI EXAMPLE XVII A foam was prepared using 200 g of resin prepared according to example XVI. The resin was mixed with 2 g of silicone surfactant. 6 g of n-hexane. and 40 g of ligninsulphonate. 25 g of catalyst (phosphoric acid sulphuric acid 1.4 Butanediol(4 2 4.5 pbw) was added under agitation and the mixture allowed to expand. The foam had a very fine cell structure. a density of 13.5

gk/m and showed no 2nd exotherm.

EXAMPLE XVIII Using the method of example XIII a resin was prepared from.

g of furfurylalcohol.

2 g of silicone surfactant.

12 g trichloro-trifluor ethane,

20 g of ligninsulphonate.

30 g of a catalyst mixture (o-phosphoric acid sulphuric acid 1.4 Butanediol 4 2 4.5 pbw). The foam had a fine cell-structure and good mechanical properties. The density was 20.3 kg/m.

Example XX Using the method of example Xlll a resin was prepared from.

3.0 kg of urea 15.8 kg of paraformaldehyde 19.8 kg of furfurylalcohol (molar ratio 1 l 4).

The resin obtained was similar to the resin of example Xlll.

Example XXl A foam was prepared using.

100 g of resin. prepared according to example XX l g of silicone surfactant (1 g of trichloro-trifluoro-ethane and as catalyst g of a mixture of o-phosphoric acid (87%) phuric acid 1.4 Butanediol t4 Z 4.5 pbw).

The foam had a very fine cell-structure and good mechanical properties. No second exotherm was observed.

: sul- Example XXII Using the method of example Xlll a resin was prepared from 12 kg of urea 3 kg of paraform aldehyde 9.8 kg of furfurylalcohol (molar ratio 1 0.5 0.5).

The resin obtained was similar to the resin of example Xlll.

Example XXlll A foam was prepared using l00 g of resin. prepared according to example XXll 50 g of Furan-resin. prepared according to example Xll 50 g of furfurylalcohol 2 g of silicone surfactant 6 g of n-Hexane and as a catalyst 30 g of a mixture of o-phosphoric acid sulphuric acid I 1.4 Butanediol (-l 2 4.5 pbw).

The foam had fine cell-structure and was tough and resilent. No second exotherm was observed.

Example XXIV Example XXV A foam was prepared using.

[00 g of resin prepared according to example XXIV l g of a silicone surfactant and as a catalyst 8 g of a mixture of o-phosphoric acid sulphuric acid 1.4 Butanediol (-l 2 4.5 pbw).

Creamtime was 27 see. rise time 41 sec. Another foam was prepared using 69.5 g of resin prepared according to example XXIV 30.5 g of fur-an resin prepared according to example XII l g of silicone surfactant and as a catalyst 10 g of the acid catalyst.

Cream time was 27 seconds. rise time 41 seconds.

Example XXVl Resins were prepared using the method described in example Xlll. replacing urea by a. urea and thio-urea l 0.5 molar ratio b. melamine and urea l 3 molar ratio.

Resins were obtained from which foams could be prepared using formulations similar to those in example XXV.

Example XXVll A foam was prepared as described in example lX using the undermentioned formulation.

Speciments measuring 80 mm X mm X 300 mm were cut from the foam and were adhesively banded and clamped to the flat vibration plate of a PYE LING generator and vibrated at a range of frequencies and amplitudes of periods of 50 minutes as shown in table F. No evidence of failure was observed and on retesting no reduction in compression properties was found.

40 pbw furan resin. pbw urea formaldehydr furfuryl alcolol resin. 20 pbw ammoniumligninsulphonate. 0.2 pbw silicone cell control agent and o pbw freon l 13 to which was added 4.8 pbw propan-2- o] and 7.2 pbw tetraphosphoric acid.

Example XXVlll Foams were prepared using the formulations given in table G.

Components A and B were mixed and the foams al lowed to rise in an aluminium mould.

The density and the mechanical properties are shown in table G below. Also the oxygen index was measured. Two different types of catalyst-mixtures are used with propan-l-ol and 1.4 Butanediol respectively as diluent for the acid. The alcohol type has an influence on the foam density. propan-Z-ol giving lower densities than Butanediol. Oxygene-index is slightly improved by use of propan-Z-ol. It is noted that different types of endpoints are observed in the test.

In fact no real burning of the foam takes place. ln foam No 1 afterglow is seen corresponding to a second exotherm found in this foam.

All oxygen indices are high compared to other materials. A list of oxygen indices for other foams is given in Table H.

Table ll Formulation Number a h c Ll e 1 Component A Furfuryl Alcohol g. 20 Furan-resin g 21! UFF-resin(1:3:3l (all Silicone surfactant g. l Lignin-sulphonate g. Ill Dimethoxymethane g. 8 Hexane g.

Component B Phosphoric Acid g. 5.4 5.3 6.7 6.7 $3 5.3 Sulphuric Acid g. 2.8 2.7 .3 3.3 2.7 2.7 Propan-I-ol g. 8 H) K Butane Diol g. 6.1 7.5 (ml) 50 31.8 14.6 ll.3 1*] [30 Density Kgm Compression Props. Modulus KNm"- 25111) [251] 2U!) 9U 23." 1H0 I119; Stress KNm )2 48 11.7 5.6 15.7 11.8 Zil'zl Stress KNm Ill: 47 Ill) 5.8 Hm: 11.6 30% Stress K'Nm' 2 Ill) 47 ll] 6.11 lfxX l1.9

Critical Oxygen 37.8 38.2 41.9 44.8 38.1 39.5 index flashed slou flashed l'lashed flashed flashed after flash slight after glow glou Table I Critical oxygen index was 48.4. Comparison of oxygen index for \arious organic foams Example XXX Material oxygen index 30 Foams were prepared using the formulations given in 30 table .1. Component A and component B were mixed Polystyrene tire retardant 3l pohurethum 33 and the foam allowed to use. z p'y firs fsmrdiml From the results it can be seen that the density is de- \'tsocyanurutc Phenol t'ormalrlehxde 3U pendent on the t pc of l1lle r an cl that dcllhll) is in- 35 creased by Increased levels oi llgnm-sulphonate. A high level of lignin-sulphonate will also increase the critical oxygen index.

Table K Formulation Number i j k e l Filler type talc MgSO; Lignin-sulphonote Le\el g. 21) It) 2U 4U Densit lx'gm 9.9 ll.() 9.2 13.0 19.4

Compressive Props. Modulus KNm 65 393 220 200 740 Stress KNm 4.5 [(1.1] 10.5 1L8 13.5 1' Stress KNm' 5.9 [0.3 ll).7 ll.(| 23.4 3091' Stress KNm' 6.8 10.8 10.) l L9 23.5

Critical Oxygen 40.0 411.5 324.7 39.7 J l .9 index flashed flashed flashed flashed flashed Example XXIX Formulation A foam was prepared using Component A 60 g of a resin prepared according to example X111 20 g of a furan-resin prepared according to example Xll 20 g of furfurylalcohol l g of a siliconesurfactant 20 g of a ligninsulphonate 8 g of Dimethoxymethane. and

as a catalyst a mixture of 12.8 g o-phosphoric acid 3.2 g methanol.

The foam had a density of 16.0 kg/m.

Mechanical properties were modulus 430 KN/m 20 g Furfuryl Alcohol, 20 g prepolymer. g urea/- formaldehyde furfuryl alcohol prepolymer. l g silicone.

and filler (see table). 8 g dimethoxymethane Component B 60 8 g propan-2-ol, 5.3 g o-phosphoric acid. 2.7 g sulphuric acid.

Example XXXI Foams were prepared using the formulations given in 5 table K.

The UF-resin was prepared according to example Xlll except that furfurylalcohol was replaced by ethyleneglycol. The furan resin was a commercial resin Durez 16470 from Hooker Chemicals.

All foams had a vcr v fine cell-structure and showed a good resistance to vibrational fatigue. No second exothcrm was observed in the foams.

maldehvde-furfurvlalcohol resin (UFF-resin) was prepared according to example Xlll.

From the results of the test for second exotherm it is seen that Table L 5 1. Foams \vithout UFF-resm have a second exotherm "l I S i Q When the content of furan'resin is about 50 percent. Fumn-rusm 5 I: 25 25 LF-resin In m 5 1 The exotherm can be removed by addition of sufficient f I5 35 paraformaldehvde. However. increased levels of para- Pairalnrmaltlch} do 4 4 8 h 3 SlllCUllL mat-ram i l l formalde h de reduce the foam-densities (foams No a, b Freon 1|. 6 t e h 6 HI and c). l'alc :5 :5 3.5 2.5 2.5 '1 wphmphwiu Add 8 x 8 x x when higher amounts of furan-resln are used the Sulphuric ma 4 4 4 4 4 densities are increased. but the second exotherm can- PP -P l? 1 l not be removed bv high levels of paraformaldehvde rcamtimuscc (it) 56 Fri 5. g Rtscllmcmtv. l5 l5 i: h 4 (Foamb NO and J)- a i M 5 l5 When low amounts of UFFresm are included in the il\. ILFHP. klll'lllg I l t 3nd Wnhflm test 3W 3W 3W foamformulatlons the second exotherm is removed by in ion degrees 1 low amounts of paratormaldeh vde (Foams No g and I1) giving an acceptable density. When increased amounts of UFF-resin are employed it is possible to make foams Eum le XXX" 30 without second exotherm having a sufficient high denp sit v and mechanical properties for handling in insula- A foam was prepared by mixing tion work.

TABLE M Foam No. a b c d e l g h l L'l-F-resin I13.1 5 5 15 Furan-resin 5U 5U 5U 7U 9U 9U 47 5 47.5 60 Furturvl alcohol 5U 5U 5U 3t) 10 ll) 47 5 47.5 I Silicone surfactant 2 2 2 2 I I I I I Paraformaldehvde I J l 2 l 2 4 I2 I 3 lignin sulphonate 375 17 s 375 17 Carbon-Black lll Talcurn 5 5 2H Freonll3 l2 i: I: 13 1: l2 H;,PO,-H2S04 l -l Butanediol 4.3.4.5 4s 4a 4n H P0, H. .so. lsopropanol 2: :3 48 48 48 32 32 (ream time Sec. 48 3h 3] 43 J) 48 48 45 48 Rise time sec. 20 3 3 5 l7 ll 20 l9 l9 Densit) kg/m as an 133 22.5 20 m1 11.6 20.0 Maxlemperature of 2nd e\otherm C 5-1-0 Slit) Zllll 220 625 64H 5-) 201) ZllU 50 g of a resin prepared according to example Xlll E I XXX, 35 g of a furan-resin prepared according to example xamp e Xll 45 A resin was prepared according to example XIV exl5 g of furfurvlalcohol cept that propyleneglycol was replaced by ethylene glyg of silicone surfactant col. lO g of phenol A foam was prepared by mixing 30 g of ammonium lignin-sulphonate 25 g of said resin 6 g of freon I I3 30 25 g of furfurylalcohol To this mixture was added as catalyst l g of siliconesurfactant 8 g of o-phosphoric acid 4 g of paraformaldehyde 4 g of sulphuric acid 2.5 g of talc 9 g of 1.4 Butanediol 6 g of Freon 113 under vigorous stirring. C reamtime was 49 sec. rise- To this mixture was added under stirring time 4| sec. Density 22 kg/m. 10 percent compressive 8 g of o-phosphoric acid (87%) strength was 0.34 kg/cm 4 g of sulphuric acid The foam was placed at 250C for about l hour. The l2 g of propan-2-ol. foam becamse more brittle and the compressive The cream time was 56 sec, rise time 8 sec. The strength was 0.36 kg/cm'- 60 foam was tough and had a fine cell-structure. The densitv was 16.2 kg/m. The foam had no second exo- Example XXXlll them Foams were prepared using the formulations given in Another foam was prepared using the same formulatable L. tion, except that 25 g of furfurylalcohol was replaced by The furan-resin used in foams No a, g, It and i was prepared according to example Xll. The resin used in foams No b. r, d, e and f was a commercial furan-resin (Durez l647l) from Hooker Chemicals). The urea-forl2.5 g of furfurylalcohol, and [2.5 g of a commercial coprepolymer of furfur vlalcohol and 12 percent formaldehyde.

21 The cream time as 56 sec.. rise time 4 sec. Density 26 kg/m". The foam had very fine cell-size and was tough. No second exotherm was observed.

Example XXXV Foams were prepared using the formulation given in table M below. The foam densities were measured and the results plotted on a triangular diagram, FIG. 6. The coordinates were Furfuryl alcohol. Furan resin. and Urea-formaldehydefurfurylalcohol resin (molar ratio 1:313).

From FIG. 6 it appears that low density foams kg/m) are found in the area of a. less than 40 parts of furan resin. plus b. more than 35 parts of furfuryl alcohol.

A borderline. representing 40 parts of furan resin. can be drawn separating foams with densities below and above 40 kg/m".

Table N Furfuryl- Foam L FF resin. Furan resin. alcohol. Density, No. parts parts parts ltglm" I IO 80 l U HIS 2 Ill 70 Ill 76 3 Ill 5U 4U 5K 4 l5 fill 50 5 2U 70 H) K: 6 2U 5U 3U 56 7 I5 60 I5 44 b 25 35 -l(l I 7 MI 51) III -17 Ill 35 35 l l 4U ll) 45 l 2 4U 2U 40 l (1 l 3 5U 2U 3U :4 I4 5 40 ll I5 S 30 25 lb XII IU I0 4 I7 (15 30 5 32 Example XXXVI Two foams were prepared. using UFF resin. prepared according to Example XIII on g furan resin. prepared according to Example XII 40 g silicone surfactant l g n-hesane 3 g filler .v g H ,PO,:H- .SO.: [.4 butanediol (-klz-LS) I25 g In both foams dextrose monohydrate was used as a filler.

In foam u: .r equals: 10 g dextrose in foam h: .v equals: 40 g dextrose foam properties: foam a foam h density 25.4 kg/m 92.1 lag/m 10% compressive strength 62 lrN/m 338 kN/m critical oxygen index lastm (1 2863-) 3] 38 1. I00 parts by weight of the polymerization product. at least 50 parts by weight of which are derived from furfuryl alcohol. of (a) l0 to parts by weight of a furfuryl alcohol resin. b) l0 to parts by weight of a urea-formaldehydefurfuryl alcohol resin in a molar ratio range of I11 to l0:0.5 to 12:05. and (c) the remainer being free furfuryl alcohol. polymerized in the presence of a strong acid catalyst and a blowing agent; and

2. up to I00 parts by weight of filler.

2. A synthetic foam according to claim I wherein the molar ratio of formaldehyde to urea is between 111 and 6:1.

3. A synthetic foam according to claim 1 wherein said filler is capable of chemically reacting with said polymer.

4. A synthetic foam according to claim 3 wherein said filler is a material containing hydroxyl and/or carbonyl groups.

5. A synthetic foam according to claim 4 wherein said filler is a lignin containing material.

6. A synthetic foam according to claim 5 wherein said filler is lignin sulphonate.

7. A synthetic foam according to claim I wherein said strong acid catalyst is selected from the group consisting of phosphoric acid and a mixture of phosphoric acid and sulphuric acid.

8. A process for preparing a synthetic furfuryl alcohol polymer foam having a density of at least about 20 kg/m and substantially no exotherm at 200C. comprising polymerizing in the presence of a strong acid catalyst and a blowing agent a feed mixture of A. free furfuryl alcohol.

B. IO to 75 parts by weight ofa furfuryl alcohol resin.

and

C. 10 to 80 parts by weight of a urea-formaldehydefurfuryl alcohol resin in a molar ratio of 1:1 to l0:0.5 to 1220.5. said free furfuryl alcohol being present in an amount sufficient to give a total feed mixture of parts by weight. to produce as a polymerization product said synthetic furfuryl alcohol polymer foam at least 50 parts by weight of which are derived from furfuryl alcohol. based on I00 parts by weight of the polymerization product.

9. A process according to claim 8 wherein the ratio of formaldehyde to urea is lzl to 6:1.

10. A process according to claim 8 further including incorporating into said polymer a filler reactive with at least one of components (A). (B), and (C).

11. A process according to claim 10 wherein said filler contains hydroxyl or carbonyl groups.

12. A process according to claim 11 wherein said filler is lignin.

13. A process according to claim 12 wherein said filler is lignin sulphonate.

14. A process according to claim 8 characterized in that said urea-formaldehyde furfuryl alcohol resin has a urea to formaldehyde molar ratio from about 1:1 to M0 and a urea to furfuryl alcohol molar ratio of at least H.

15. A synthetic foam according to claim 8 wherein said strong acid catalyst is selected from the group consisting of phosphoric acid and a mixture of phosphoric acid and sulphuric acid. 

1. A SYNTHETIC FURFURYL ALCOHOL POLYMER FOAM HAVING A DENSITY OF AT LEAST ABOUT 20 KG/M3 AND SUBSTANTIALLY NO EXOTHERM AT 200*C. COMPRISING:
 1. 100 PARTS BY WEIGHT OF THE POLYMERIZATION PRODUCT AT LEAST 50 PARTS BY WEIGHT OF WHICH ARE DERIVED FROM FURFURYL ALCOHOL, OF (A) 10 TO 75 PARTS BY WEIGHT OF A FURFURYL ALCOHOL RESIN, (B) 10 TO 80 PARTS BY WEIGHT OF UREA-FOR-
 2. UP TO 100 PARTS BY WEIGHT OF FILLER.
 2. up to 100 parts by weight of filler.
 2. A synthetic foam according to claim 1 wherein the molar ratio of formaldehyde to urea is between 1:1 and 6:1.
 3. A synthetic foam according to claim 1 wherein said filler is capable of chemically reacting with said polymer.
 4. A synthetic foam according to claim 3 wherein said filler is a material containing hydroxyl and/or carbonyl groups.
 5. A synthetic foam according to claim 4 wherein said filler is a lignin containing material.
 6. A synthetic foam according to claim 5 wherein said filler is lignin sulphonate.
 7. A synthetic foam according to claim 1 wherein said strong acid catalyst is selected from the group consisting of phosphoric acid and a mixture of phosphoric acid and sulphuric acid.
 8. A process for preparing a synthetic furfuryl alcohol polymer foam having a density of at least about 20 kg/m3 and substantially no exotherm at 200*C. comprising polymerizing in the presence of a strong acid catalyst and a blowing agent a feed mixture of A. free furfuryl alcohol, B. 10 to 75 parts by weight of a furfuryl alcohol resin, and C. 10 to 80 parts by weight of a urea-formaldehydefurfuryl alcohol resin in a molar ratio of 1:1 to 10:0.5 to 12:0.5, said free furfuryl alcohol being present in an amount sufficient to give a total feed mixture of 100 parts by weight, to produce as a polymerization product said synthetic furfuryl alcohol polymer foam at least 50 parts by weight of which are derived from furfuryl alcohol, based on 100 parts by weight of the polymerization product.
 9. A process according to claim 8 wherein the ratio of formaldehyde to urea is 1:1 to 6:1.
 10. A process according to claim 8 further including incorporating into said polymer a filler reactive with at least one of components (A), (B), and (C).
 11. A process according to claim 10 wherein said filler contains hydroxyl or carbonyl groups.
 12. A process according to claim 11 wherein said filler is lignin.
 13. A process according to claim 12 wherein said filler is lignin sulphonate.
 14. A process according to claim 8 characterized in that said urea-formaldehyde furfuryl alcohol resin has a urea to formaldehyde molar ratio from about 1:1 to 1:10 and a urea to furfuryl alcohol molar ratio of at least 1:1.
 15. A synthetic foam according to claim 8 wherein said strong acid catalyst is selected from the group consisting of phosphoric acid and a mixture of phosphoric acid and sulphuric acid. 